Urethane resins

ABSTRACT

Amine-terminated urethane oligomer compositions are described that include very high oligomer concentrations. The compositions are melts of the amine-terminated oligomers. The compositions can include one or more property modifiers. The compositions are useful in the formation of crosslinked copolymers, especially with epoxy resins. The resulting copolymers are useful in the formation of coatings.

This is a divisional of copending application of Ser. No. 09/089,530,filed on Jun. 3, 1998, which has now issued as U.S. Pat. No. 6,218,500.

FIELD OF THE INVENTION

The invention relates to compositions comprising urethane resins, inparticular, amine-terminated urethane oligomers. The invention furtherrelates to polymers prepared by combining urethane oligomers withcrosslinking agents and to coatings formed from the resulting polymers.

BACKGROUND OF THE INVENTION

Polyurethanes are used in a variety of commercial applications for theproduction of products such as fibers, adhesives, coatings, elastomersand foams. Polyurethane coatings can have desirable properties includinghigh gloss, chemical resistance and abrasion resistance. Preferredurethane coatings also display flexibility, impact resistance, andtoughness. For use as coatings, the composition must be prepared in aform that can be spread on the relevant surface. The curing orcrosslinking process then completes polymer formation as any remainingvolatiles evaporate.

Urethane coatings can be supplied in the form of a two componentformulation, where the two components are mixed prior to application toa surface. One component includes urethane oligomers with suitablefunctional groups available for crosslinking. The second componentincludes a crosslinking agent that can react with the functional groupsof the urethane oligomers.

SUMMARY OF THE INVENTION

The present invention involves the formation of compositions with veryhigh concentrations of amine-terminated urethane oligomers. Theoligomers of compositions generally are unsolvated. The compositions caninclude plasticizers, viscosity modifiers and other additives. Thecompositions generally have sufficiently low viscosities such that theycan be blended with appropriate crosslinking compositions to formdesirable polymers. The high solid, urethane oligomer compositions haveimproved properties for the formation of coatings. In particular, thepolymer compositions can be applied in relatively thick layers withouthindering the curing process to form high quality coatings.

In a first aspect, the invention features a composition includinggreater than about 55 percent by weight amine-terminated urethaneoligomers. In selected embodiments the composition includes from about60 percent to about 90 percent by weight amine-terminated urethaneoligomers. In other embodiments the composition includes from about 65percent to about 80 percent by weight amine-terminated urethaneoligomers.

The composition can further include an aqueous viscosity modifyingagent. The aqueous viscosity modifying agent can include greater thanabout 30 percent by weight volatile alcohol. The composition also caninclude volatile organic acids, with the composition preferablycomprising less than about 10 percent and more preferably less thanabout 1 percent by mole equivalent of carboxylate groups of the volatileorganic acids relative to amine groups of the amine-terminated urethaneoligomers. The amine-terminated urethane oligomers can include primaryamine-terminated oligomers. The amine-terminated urethane oligomers caninclude multifunctional amine moieties bonded at secondary amine sitesto isocyanate functional groups of a urethane oligomer to form carbamatelinkages. Suitable multifunctional amine moieties include N-(aminoethyl)piperazine moieties.

In another aspect, the invention features a kit including:

a) a composition comprising greater than about 55 percent by weightamine-terminated urethane oligomers; and

b) a polyepoxide compound in a container separate from the compositioncomprising amine-terminated urethane oligomers.

The polyepoxide can be a polyglycidyl ether of a polyphenol, apolyglycidyl ether of aliphatic polyol with 2 to 4 hydroxyl groups, ormixtures thereof. The ratio of active hydrogens in amine functionalgroups to epoxide groups preferably ranges from about 1:1 to about1.75:1.

In another aspect, the invention features a method of producing anamine-terminated urethane oligomer composition comprising the steps of

a) adding water to a polyketimine functionalized urethane oligomer; and

b) removing ketone to form a composition comprising greater than about55 percent by weight amine-terminated urethane oligomer.

In another aspect, the invention features a polymer coating including anepoxy crosslinked amine-terminated urethane polymer, the coating beingformed by curing a mixture of polyepoxides and a composition comprisinggreater than about 55 percent by weight amine-terminated urethaneoligomers.

In another aspect, the invention features a method of forming a coatingcomprising the steps of spreading a mixture on a surface such that itcan cure, the mixture obtained by mixing polyepoxides with a compositioncomprising greater than about 55 percent by weight amine-terminatedurethane oligomers. The surface can be concrete and can form a wall or afloor.

Other features and advantages of the invention follow from the detaileddescription of the invention and claims below.

DETAILED DESCRIPTION

Novel compositions include surprisingly high proportions ofamine-terminated urethane oligomers while generally exhibiting suitablerheological properties. Amine-terminated urethane oligomers have aminefunctional groups available for further reaction with, for example, acrosslinking agent. The novel compositions generally are roomtemperature “melts” (i.e., flowable polymer compositions where thepolymer is not dissolved in a solvent) that may include viscositymodifiers to reduce the viscosity for easier handling. Some of thesecompositions have qualitatively different properties than compositionsinvolving aqueous emulsions of amine-terminated urethane oligomers. Theimproved compositions have excellent properties conducive to theformation of coatings upon mixing with a crosslinking agent.

The formation of the amine-terminated urethane oligomers first involvesgeneration of an isocyanate functional urethane oligomer by the reactionof a polyisocyanate compound with a compound having active hydrogenssuch as a polyol, an amine or a thiol. The isocyanate functionalurethane oligomer is then reacted with a compound having a single activehydrogen and at least one protected primary amine group. The protectedamine group generally involves a ketimine formed by reacting a ketonewith the primary amine. After completing formation of the ketimineterminated urethane oligomer, the ketimine can be hydrolyzed to form theamine-terminated urethane oligomer.

The amine-terminated urethane oligomers can be crosslinked at the aminefunctional groups to form polymers. Preferred crosslinking agentsinclude epoxy resins and acrylates. The resulting polymer can have theadvantageous properties of a polyurethane together with other propertiescontributed by the crosslinking agent.

An amine-terminated urethane oligomer composition has several advantagesover compositions with corresponding oligomers in aqueous emulsions. Forexample, the higher solid concentration means that a smaller volume isrequired to hold an equivalent amount of oligomer. Furthermore,significant quantities of volatile organic acids used to form theaqueous emulsion are not needed. The volatile organic acids slow thecuring process since they must evaporate to permit the crosslinkingreaction to proceed. In addition, thicker layers of the high solidmaterial can be formed in a single application of the coating sincebubble formation from the evaporation of organic acid and water is lessof a concern.

A. Formation of Urethane Oligomers

First, an isocyanate terminated urethane oligomer is formed. This stepcan be carried out conventionally through reaction of polyisocyanates,especially diisocyanates and triisocyanates, with polyfunctional organiccompounds having at least two active hydrogen atoms for reaction withthe isocyanate functional groups. In general, the isocyanate functionalgroups should be in excess relative to the active hydrogen functionalgroups. The ratio of isocyanate functional groups to active hydrogenatoms preferably is from about 1.01:1 to about 5:1, and more preferablyfrom about 1.1:1 to about 3:1.

Representative polyisocyanates include, for example, toluenediisocyanate, 4,4′-diphenyl diisocyanate, 4,4′-diphenylmethanediisocyanate, 4,4-diphenyl-ether diisocyanate, dianisidine diisocyanate,1,5-naphthalene diisocyanate, p-phenylene diisocyanate, trimethylenediisocyanate, octadecylmethylene diisocyanate, 2-chloropropanediisocyanate, 4,4′-methylene-bis(phenyl isocyanate), isophoronediisocyanate, 1,6-hexamethylene diisocyanate,4,4′-methylene-bis(cyclohexyl isocyanate), 4,4′,4″-triphenyl-methanetriisocyanate, 1,3,5-benzene triisocyanate, polymethylene poly(phenylisocyanate), and mixtures thereof. Suitable polyisocyanates also includebiurets such as the biuret of 1,6-hexamethylene diisocyanate sold asTolanate HDB™ (Rhone-Poulenc, Shelton, Conn.) and isocyanurates such asthe isocyanurate of 1,6-hexamethylene diisocyanates sold as TolanateHDT™ (Rhone-Poulenc, Shelton, Conn.).

A variety of organic compounds have at least two active hydrogen atomsthat are reactive with free isocyanate groups, including polyfunctionalmercaptans, primary and secondary amines, carboxylic acids, alcohols andcombinations thereof. Suitable poly-secondary amines include, forexample, piperazine. Preferred polyols have a molecular weight fromabout 200 to about 7500. Suitable polyols include, for example, ethyleneglycol, diethylene glycol, 1,3-propylene glycol, 1,4-butane diol,glycerol, trimethylol-propane, erythritol, pentaerythritol, polyetherssuch as poly(ethylene oxide) diol and poly(propylene oxide) diol,polylactones such as polycaprolactone, and polyhydroxypolyesters ofpolycarboxylic acids such as esters of succinic acid, adipic acid,azelaic acid, sebacic acid, phthalic acid, isophthalic acid, andteraphthalic acid with polyols such as ethylene glycol, diethyleneglycol, 1,4-butane diol, trimethylolpropane, glycerol, erythritol,pentaerythritol, poly(ethylene oxide) diol, polyethyleneoxide/propyleneoxide) diol, and poly(tetramethylene oxide) diol.

Suitable urethane oligomers can be formed with pure polyols, especiallydiols. Nevertheless, it can be advantageous to add a mixture of diolsand triols. The incorporation of triols provides a more branchedstructure. When a mixture of diols and triols is used, the ratio oftriols to diols preferably is from 0.05:1 to about 2:1 and morepreferably from about 0.1:1 to about 1.25:1.

Preparation of the isocyanate functional polyurethane oligomers can beaccomplished by a one-stage process. In this process, the reactantsincluding at least one polyisocyanate compound and at least one polyolare mixed to initiate the reaction. The reaction can be carried outunder anhydrous conditions at a temperature from about 50° C. to about80° C. for several hours. The reaction to form the isocyanate functionalpolyurethane can be carried out in a melt or in solution. In otherwords, an inert organic solvent optionally can be added when forming thereaction mixture. Suitable organic solvents include, for example, methylacetate, ethyl acetate, amyl acetate, acetone, methyl ethyl ketone,diethyl ketone, methylisobutyl ketone, dimethyl formamide, dioxane, andmethyl pyrrolidone.

B. Amine-Terminated Urethane Oligomers

The isocyanate functional urethane oligomers can be reacted with atleast one ketimine or polyketimine to form ketimine functionalpolyurethane oligomers. The ketimine and polyketiimines can be formed byreacting primary amines with a ketone as a removable protecting group.Ketones enter into a condensation reaction with the primary amine, wherethe carbonyl of the ketone combines with the two active hydrogens of theprimary amine group to form water and a ketimine If the correspondingunprotected primary amines are reacted with the isocyanate functionalpolyurethanes, crosslinking occurs due to reaction of the amine groupswith the isocyanates, which can result in gelation if sufficient crossinking takes place.

Appropriate mono- or poly-primary amines have another reactive hydrogenthat does not react with the ketone, for example a secondary amine, ahydroxyl or a thiol group. In other words, the primary amine can be amonosecondary amino, monohydroxy, or monothio substituted, mono- orpolyfunctional primary amine. The ketimine has the general formula:

H—X—R₁(N=R₂)_(n),

where n is at least one and where X can be O (hydroxyl), NR₃ (secondaryamine) or S (thiol). R₂ is the residue of the ketone that is formed intothe ketimine. R₁ can be an aliphatic, cycloaliphatic, heterocyclic oraromatic hydrocarbon moiety, and may be saturated or unsaturated. R₁ canbe extensively branched and can bear one or more additional ketiminefunctional groups. R₁ contains preferably 2-8 carbon atoms and morepreferably 2-4 carbon atoms. R₃ can be an aliphatic, cycloaliphatic,heterocyclic or aromatic hydrocarbon moiety, and can be saturated orunsaturated. R₃ can be bonded to R₁ to form a heterocyclic structure. R₃contains preferably 1-8 carbon atoms and more preferably 1-4 carbonatoms. There are few examples of commercially available monosecondaryamino, monoprimary amines. Suitable commercially available compoundsinclude, for example, N-(ω-aminoalkyl)-substituted diazacyloalkanes oralkenes such as N-(aminoethyl)piperazine and N-alkyl-1,ω-diaminoalkanessuch as N-methyl-1,3-propanediamine. Similarly, commercially-availablemonosecondary amino, polyfunctional primary amines are likewise few innumber. Two examples of commercially available compounds containing twoprimary amine groups and one secondary amine group are diethylenetriamine (D.E.H. 20™, Dow Chemical, Midland, Mich.) andbis(hexamethylene)triamine (DuPont, Wilmington, Del.).

Examples of suitable monohydroxy, monoprimary amines include, forexample, monoethanolamine, monoisopropanol amine, and3-amino-1-propanol. Suitable monohydroxy, polyfunctional primaryaminesinclude, for example, 1,3-diamino-2-hydroxypropane. Monothio-, mono- orpolyfunctional primary amines can be prepared by the reaction ofhydrogen sulfide or certain mercaptans with unsaturated monoamines suchas alkyl amines including, for example, butenyl amines and cyclohexenylamine. Examples of useful mercaptans for these syntheses include, forexample, 1,3 propanedithiol, 1,4 butanedithiol, and 1,4 benzenedithiol.

Suitable ketones for forming the ketimine include, for example, acetone,methyl ethyl ketone, diethyl ketone, methyl isobutyl ketone, dibutylketone, diisobutyl ketone, methyl isopropyl ketone, methyl octyl ketone,ethyl butyl ketone, and dioctyl ketone. The ketimines or polyketiminescan be prepared, for example, according to the methods disclosed in U.S.Pat. No. 3,291,775 or as described in the examples below.

Note that the product water can be removed, for example by evaporation,to increase the formation of ketimine If the water is not removed, aproportion of the primary amine remains unprotected. This unprotectedprimary amine along with the additional reactive hydrogen in themolecule can react with isocyanate groups to crosslink the urethaneoligomers. Generally, reaction with the primary amines results in alower crosslinking density since amide formation can prevent fullcrosslinking with both active hydrogens of the primary amine. As notedbelow, crosslinking density affects the properties of the resultingpolymer and coating formed from the polymer. On the other hand, theprimary amines react quickly with the isocyanate groups such that thematerial very quickly can become too viscous to handle easily if theprimary amine concentration is too high. Nevertheless, since the ketonecan be present in a large excess, the presence of product water may notresult in a sufficiently large quantity of free primary amine tosignificantly crosslink the urethane oligomers.

The ketimines or polyketimines are reacted with the isocyanatefunctional urethane oligomers to form ketimine functional urethaneoligomers. The active hydrogen associated with the X-H group of theketimine or polyketimine reacts with an isocyanate functional group. Theresulting compounds are ketimine or polyketimine terminated urethaneoligomers represented by the formula:

R—(NHCOX—R₁(N=R₂)_(n))_(m),

where R is the urethane oligomer backbone and m is the number ofisocyanate functional groups in the original urethane oligomer. X, R₁,R₂ and n are defined above.

Generally, approximately one equivalent of ketimine composition is addedper isocyanate (NCO) equivalent of urethane oligomer. If the ratios ofequivalents are not one-to-one, there may be unreacted isocyanates oractive hydrogen groups that contribute to any later crosslinkingreaction, resulting in an overall reduction in crosslinking density.Preferably, the ratio of equivalents of ketimine to NCO ranges fromabout 0.7 to about 1.3, and more preferably from about 0.8 to about 1.2.

To complete formation of the primary amine-terminated urethaneoligomers, the ketone protecting groups are removed by hydrolyzing theketimine. One way of accomplishing this hydrolysis is though addition ofexcess water and a volatile organic acid. Addition of excess water and avolatile organic acid results in formation of an aqueous dispersion ofthe amine-cerminated urethane oligomers. The organic acid is used toprotonate the amine groups to assist with the dispersion of the compoundin water.

It has been discovered that a second way can be used to perform thehydrolysis. In this second approach, a smaller amount of water can beadded to the ketimine terminated urethane oligomers. The smaller amountwater hydrolyzes the ketimine to form the primary amine withoutformation of an aqueous dispersion. The resulting amine-terminatedurethane oligomer has the formula:

R—(NHCOX—R₁(NH₂)_(n))_(m),

where R, R₁, R₂, X, n and m are defined above. Since the resultingcompound is not dispersed in water, a smaller quantity of volatileorganic acid can be added as a viscosity modifier. Similarly, no organicacid can be added.

Following hydrolysis of the ketimine, the ketone is evaporated to yielda “melt” of the oligomer. In this way, a composition can be formed withvery high proportions of amine-terminated urethane oligomers. Afterremoval of the ketone, the composition generally comprises greater thanabout 55 percent by weight of the amine-terminated urethane oligomers,preferably from about 65 percent by weight to about 90 percent by weightand more preferably from about 70 percent by weight to about 80 percentby weight.

The added water can include miscible organic components that function asviscosity modifying agents. For example, a quantity of volatile organicacids, optionally, can be added. The composition generally includes lessthan about 10 percent, preferably less than about 1 percent, by moleequivalent of carboxylate groups of the volatile organic acids relativeto all the amine groups (primary, secondary and tertiary) found in theamine-terminated urethane oligomers. Suitable organic acids include, forexample, acetic acid. Other suitable miscible organic componentsinclude, for example, alcohols such as benzyl alcohol, n-butanol andisopropyl alcohol. When methyl ethyl ketone is used as the ketoneprotecting group, isopropyl alcohol is preferred since isopropyl alcoholforms an azeotrope with methyl ethyl ketone that assists with theremoval of the ketone.

Effectively all or most of the ketone generally is removed from thecomposition since residual ketone can interfere with the eventualcrosslinking reaction, although a small amount of ketone does notinhibit significantly the eventual crosslinking reaction. The finalcomposition includes the amine-terminated urethane oligomer, anyunreacted and unevaporated water, and any unevaporated organic solvent.The remaining water and organic solvent such as alcohol can act asplasticizers and/or viscosity modifiers. While the resultingamine-terminated urethane oligomer compositions have high viscosities,they are flowable. Therefore, they can be combined with a crosslinkingagent to form a crosslinked polymer. Additional processing aids such asplasticizers and viscosity modifiers can be added to modify theproperties of the composition. Similarly, additional additives can beadded to a second component that is combined with the urethane oligomersto form a copolymer.

C. Crosslinked Urethanes (Copolymers)

The amine-terminated urethane oligomers can be reacted with acrosslinking agent to form a copolymer. Suitable crosslinking agentsinclude, for example, monomers or oligomers with epoxy or acrylatefunctional groups. Suitable acrylate crosslinking agents include, forexample, trimethylol propane triacrylate (TMPTA) and urethane acrylates.Epoxy based crosslinking agents are of particular interest.

Epoxy resins of interest contain at least one, but preferably more thanone, 1,2-epoxy group of the formula:

Suitable epoxy resins can be saturated or unsaturated, aliphatic,cycloaliphatic, aromatic, or heterocyclic. The epoxy resins have anaverage molecular weight preferably from about 100 to about 2000 andmore preferably from about 140 to about 200. A selected epoxy resin canbe supplied in the form of a solution in an organic solvent, water, or acombination of water and a water miscible organic solvent.Alternatively, the epoxy resin can be supplied in an unsolvated form,substantially free of organic solvent and water.

Examples of suitable epoxy resins include, for example, polyepoxidescontaining pendant and/or terminal 1,2-epoxy groups, such as thepolyglycidyl ethers of polyphenols. Polyglycidyl ethers of polyphenolsmay be prepared, for example, by etherification of a polyphenol withepichlorohydrin or dichlorohydrin in the presence of base. Examples ofsuitable polyphenols include 1,1-bis(4-hydroxyphenyl)ethane,2,2-bis(4-hydroxyphenyl)propane, 1,1-bis(4-hydroxyphenyl)isobutane,2,2-bis(4-hydroxy-t-butylphenyl)propane,bis(2-hydroxy-1,5-dihydroxy)naphthalene,1,1-bis(4-hydroxy-3-allyphenyl)ethane, and hydrogenated derivativesthereof. The polyglycidyl ethers of polyphenols of various molecularweights can be produced, for example, by varying the molar ratio ofepichlorohydrin to polyphenol.

Useful polyepoxides also include, for example, the polyglycidyl ethersof mononuclear polyhydric phenols such as the polyglycidyl ethers ofrescinol, pyrogallol, hydroquinone and pyrocatechol. Suitable epoxyresins also include the polyglycidyl ethers of polyhydric alcohols suchas the reaction products of epchlorohydrin or dichlorohydrin with(C₂-C₂₀) aliphatic or cycloaliphatic compounds containing from two tofour hydroxyl groups including, for example, ethylene glycol, diethyleneglycol, triethylene glycol, dipropylene glycol, tripropylene glycol,propane diols, pentane diols, glycerol, 1,2-hexanetriol, pentaerythritoland 2,2-bis(4-hydroxy cyclohexyl)propane.

Suitable epoxy resins also include aliphatic, cycloaliphatic andglycidyl ether type 1,2-epoxides such as propylene oxide, styrene oxide,vinylcyclohexene dioxide, glycidol, butadiene oxide, glycidylpropionate, 3,4-epoxycyclohexylmethyl 3,4-epoxycyclohexane carboxylate,bis-(3,4-epoxy-6-methyl cyclohexyl methyl)adipate, dipentene oxide andpoly(dimethylsiloxanes) having cycloaliphatic epoxide or glycidyl ethergroups. Suitable polyepoxides additionally include polyglycidyl estersof polycarboxylic acids. Examples of which include polyglycidyl estersof bis(carboxylic acids such as adipic acid, phthalic acid and the like.

Polymerized resins containing epoxy groups can also be used. Thesepolyepoxides can be produced by addition polymerization of epoxyfunctional monomers such as glycidyl acrylate, glycidyl methacrylate,and allyl glycidyl ether, optionally in combination with ethylenicallyunsaturated monomers such as styrene, alpha-methyl styrene, alpha-ethylstyrene, vinyl toluene, t-butyl styrene, acrylamide, methylacrylamide,acrylonitrile, methacrylonitrile, ethyl methacrylate, isobutylmethacrylate, isopropyl methacrylate,isobutyl methacrylate and isobornylmethacrylate. Many additional examples of useful epoxy resins aredescribed in the Handbook of Epoxy Resins, H. Lee et al., eds., McGrawHill Book Company (1967).

Stoichiometric blends of epoxy resins and active hydrogen bearing curingagents do not necessarily provide optimal polymer properties, especiallyfor use as coatings. The ratio of 1,2-oxirane (epoxide) equivalency toactive hydrogen equivalency from the primary amines of the urethaneoligomers can be varied widely, and the resulting coatings exhibit awide range of physical property differences. Note that each primaryamine functional group is difunctional and capable of interacting withtwo epoxide groups. The ratio of 1,2-oxirane equivalency to activehydrogen equivalency can be varied from about 1:0.5 to 1:2 or higher.

Infrared analysis has shown that a slight excess of active hydrogenequivalency (about 0.9 equivalents of epoxide per active-hydrogen atom)is required to obtain complete disappearance of absorbance due to the1,2-oxirane group. Active hydrogen equivalency can be evaluated using adirect measure of isocyanate equivalency and a theoretical estimatebased on the amount of ketimine/primary amine added to form the ketiminefunctionalized urethane oligomers. The quantities of active-hydrogenatoms necessary to obtain complete disappearance of the 1,2-oxiranefunctionality can be referred to as the “optimal” quantity. At “optimum”blend ratios, the polymeric coating is nearly completely cross-linked.

As the ratio of active hydrogen atoms is increased above optimum, someof the active hydrogen atoms do not react with the epoxide groups.Excess active hydrogen atoms result in a degree of linearity, in otherwords a reduction in the cross-linking density in the cured polymer.Increasing the amount of amine active hydrogens above the level found toreact with all of the 1,2-oxirane groups can provide a polymer withincreased flexibility and decreased hardness and brittleness. Otherproperties can deteriorate if the mix ratio of the oligomer componentsare not selected properly. For example, tensile strength can droprapidly while water, chemical and abrasion resistance can be reduced.These property differences may be due to molecular configurations in thecured polymer that vary according to the amount of the excess activehydrogen atoms. As noted above, crosslinking of isocyanate groups byunprotected primary amine combined with the ketimine also can result ina reduced crosslinking density.

Consequently, the characteristics of the oligomers and their ratios canbe manipulated to produce desired properties. Typical polyurethaneproperties can be built into the urethane oligomer. Larger urethaneoligomers with slight to moderate branching are preferred. Reducedbranching of the urethane oligomers generally results in a more pliablecoating. Urethane oligomers preferably have an average molecular weightfrom about 400 to about 1200. The polyurethane-like character can beenhanced by restricting the amount of epoxide oligomer curing agent byusing a lower molecular weight epoxy.

If a suitable urethane oligomer is selected, the physical properties ofthe urethane/epoxy copolymer do not degrade as the active hydrogenatom/epoxide ratio exceeds stoichiometric, i.e., “optimal,” values. Theurethane-like properties of high abrasion resistance and gloss retentionare generally observed at blending ratios of 1.25-1.75 active hydrogenequivalents per epoxide. In certain cases, properties continue toimprove as the active hydrogen equivalent per epoxide ratio is increasedto 2:1. When active hydrogen per epoxide ratios are within the range of1.25-1.75, the copolymer formed with larger urethane oligomers exhibitswater resistance typical of films obtained with essentiallystoichiometric blends. The water resistance of the cured polymers startsto decline as the active hydrogen atom/epoxide ratio approaches andexceeds 2:1.

Urethane-epoxy blends generally exhibit a limited pot life of a fewminutes to several hours after combining the components, for film orcoating formation. Pot life has been associated with an increase inviscosity due to formation of the copolymer. When the viscosity hasincreased to the point that application becomes difficult and adversefilm appearance characteristics cannot be avoided, the effective potlife of the blend is considered exceeded.

For optimal cure conditions, the urethane oligomer composition and epoxyresin should be between about 60° F. and about 100° F., and morepreferably between about 70° F. and about 90° F. Premeasured quantitiesof the urethane oligomer composition and the epoxy resin can be pouredinto a clean container and blended thoroughly, for example, using apower mixing paddle or agitator, such as a Jiffy Mixer (distributed byJiffy Mixer Company, Inc., San Francisco, Calif.) using a high strengthindustrial drill at low speed for a minimum of 5 minutes. Followingmixing, the polymer is ready for the formation of coatings and the like.

D. Packaging and Distribution

Generally, the amine-terminated urethane oligomers and epoxy resins orother crosslinking composition are packaged and stored in separatecontainers awaiting use. Due to limited pot life, the two components ofthe copolymer are generally mixed at the site for curing of thecopolymer. For distribution, the amine-terminated urethane oligomers andthe epoxy resins preferably are packaged in containers with premeasuredquantities suitable for mixing. In other words, the contents of theurethane oligomer container are mixed with the contents of the epoxyresin container to form a copolymer mixture with desiredcharacteristics. This packaging in suitably measured quantities providesfor easy preparation of the crosslinked copolymer without the need forthe end user to measure desired amounts of the components of thecopolymer.

The two premeasured components can be placed in a single package, suchas a box or different portions of a divided package, for distribution.Alternatively, the different containers can be shipped in separatepackaging along with a instruction label indicating that one containeris to be mixed with the contents of the other container.

E. Coatings

The urethane/epoxy copolymers described above are particularly usefulfor the formation of coatings. The copolymers are preferably cured atambient temperatures following application to a substrate.Alternatively, films of the blends can be heated to speed thecrosslinking process. To form the coating, the two components of thecopolymer generally are mixed, stirred and spread. Preferred substratesinclude concrete and wood surfaces such as floors and walls.

To form a floor coating, for example, the blend can be applied using aroller from a pan, or poured onto the floor in a windrow fashion andleveled using a squeegee. The coating can be spread, for example using anotched squeegee. Alternatively, the copolymer can be spread using ascreed box to apply the material at a desired thickness over thesubstrate. The spread copolymer can be backrolled with a nap roller, ifdesired, to smooth any imperfections. The copolymer can be mixed withsand or the like to form a mortar prior to application to a surface.

Due to the high solids concentrations, i.e. low solvent concentrations,the present urethane/epoxy mixtures generally can be applied at greaterthicknesses without adversely affecting the curing properties. Inparticular, the urethane oligomer/epoxy oligomer blends can be appliedto a surface at a thickness of greater than about 1 mil, preferably fromabout 2 mils to about 200 mils. Thicker systems tend to be applied asmortar to repair eroded concrete.

Since a relatively large amount of volatile organic acid is not used toform a water emulsion, the curing rate does not depend on the rate ofevaporation of the volatile organic acid. Generally, even when appliedat relatively large thicknesses, the urethane/epoxy copolymer are dry tothe touch within about 24 hours to about 48 hours. Generally, two weeksare required for complete curing of epoxies.

F. Coating Properties

While the properties of the final copolymers are influenced by thecrosslinking agent, the urethane components have a significant influenceon the properties of the resulting copolymer. Perhaps the predominantperformance feature of polyurethane coatings that distinguishes themfrom other industrial/architectural coatings is their “toughness.” ThePaint/Coatings Dictionary, published by the Federation of Societies forCoatings Technology, 1978, defines toughness as “that property of amaterial by virtue of which it can absorb work.” “Brittle” is defined inthe same dictionary as “the opposite of tough.” Abrasion resistance is acommonly measured property in the protective coatings industry and isclosely related to toughness since it measures the work absorbingcapacity of a coating. If desired, toughness can be defined as theabrasion resistance.

Various of techniques to evaluate abrasion resistance of protectivecoatings are published by ASTM. ASTM Method D-4060-81, “AbrasionResistance of Organic Coatings by the Taber Abraser,” is perhaps themost widely used. Abrasion resistance is determined by this test interms of milligrams (mg) of coating loss per 1000 cycles of wear asapplied by a Taber Abraser. A lower value of mgs of coating lostgenerally indicates a greater ability of the protective coating toresist abrasion.

It should be noted, however, that coatings that are very soft andextensible, but yet resilient, can yield low abrasion resistant values,indicative of good abrasion resistance, under the ASTM D-4060-81 testwhile the coatings are too soft to be useful as protective coatings formany applications. Thus, depending on the overall performancerequirements of the coating system, a coating with the lowest abrasionresistance values under the ASTM D-4060-81 test may not have desiredperformance characteristics. Therefore, it is useful to combinemeasurements of abrasion resistance under the ASTM D-4060-81 test withmeasurements such as tensile strength and hardness. A coating productintended for use as an industrial floor coating must have sufficienttensile or cohesive strength to resist scratching, and sufficienthardness to resist dirt collection from industrial traffic.

Film hardness can be evaluated in accord with ASTM Method D-4366-84,“Hardness of Organic Coatings by Pendulum Damping Tests.” ASTM D-4366-84describes the use of a König hardness tester. ASTM D-4366-84 is apreferred hardness test since surface imperfections have littleinfluence on the resulting hardness measurements. Under ASTM D-4366-84,“König hardness” is defined as the “time in seconds for the swing of theKönig pendulum to decrease from 6° to 3°.” The König hardness tester iscalibrated on plate glass to yield a value of 250±10 seconds.

Tensile strength and elongation can be measured following the proceduresfound in ASTM D 2370-92. For the tests, a copolymer film is produced asa free film with a uniform thickness. The free film is formed by castingthe copolymer onto a non-stick plastic board. A tensile tester fromInstron (Canton, Mass.) is used. After completely drying, the substrateis removed from the board. The copolymer film is cut to the dimensionsspecified in the protocol and is placed in the jaws of the tensiletester. The tensile tester was set to have an elongation rate of 2inches per minute. The film was elongated until rupture of the film. Thetensile strength was determined first by the stress in pounds per squareinch (cross sectional area) required to reach the yield point where theelongation as a function of stress reaches a maximum and second by thestress required to rupture the film. Urethane films tend to stretchprior to breaking in contrast with epoxy films that are more brittle.Elongation was determined as the percent elongation at the breakingpoint.

For the measurements reported in the examples below, abrasion resistancewas measured following ASTM D-4060-81 using a Taber Abraser, Könighardness was measured following ASTM D-4366-84, and tensile strength andelongation were measured following ASTM D 2370-92.

EXAMPLES Example 1

Formation of Urethane Oligomer

Initially, a 254.48 g quantity of toluene diisocyanate (TDI) and a 330 gquantity of methyl ethyl ketone (MEK) were placed in a glass reactionflask. The TDI and MEK were bathed continuously with an inert nitrogenatmosphere while being stirred gently in the flask. The reaction flaskwas gently heated to a temperature of 140° F. At a temperature of about125° F., 34.84 g of solid 2-ethyl-2-(hydroxymethyl)-1,3-propanediol(TMP) were added to the reaction flask. After addition of the TMP, 434.2g of polytetramethylene glycol (PM-650) (average molecular weight 672for the particular lot) were added gradually to the reaction flask withan addition funnel.

With the addition of the TMP and PM-650, the exothermicity of thereaction required cooling of the flask to maintain the flask at thedesired reaction temperature of about 140° F. Upon completion of theaddition of the PM-650, the glass addition funnel was rinsed with 50 gof MEK, which was then added to the reaction flask. When the temperaturedropped below 140° F., the flask was heated to maintain the temperaturenear 140° F. The reaction was continued at or near 140° F. for about 4-6hours for completion of the prepolymer reaction.

Toluene diisocyanate (TDI) has two functional isocyanate groups yieldingan equivalent weight of 87 based on a molecular weight of 174. TMP hasthree hydroxy groups corresponding to an equivalent weight of about44.67. PM-650 has two hydroxy groups corresponding to an equivalentweight of about 334. Based on the quantities added above and the notedequivalent weights, the equivalents of TDI, TMP and PM-650 added were,respectively, 2.925, 0.780 and 1.3. This corresponds to relativeequivalents of TDI:TMP:PM-650 of 2.25:0.60:1.00.

The MEK (370 g) was the only significant volatile component of thecomposition. A total of 1093.52 g of urethane oligomer solution wasrecovered. The remaining compounds (theoretically 723.52 g) werenon-volatile. The weight percentage of the non-volatile components basedon the theoretical estimate was 723.52/1093.52=66.16%. The weightpercentage of the non-volatile component as determined with the methodof ASTM D 2369-90 was 66.97%. The remaining, unreacted NCO functionalgroups were evaluated according to ASTM procedure ASTM D-1638-74,sections 86-92. In this procedure, to determine the number of NCOfunctional groups (i.e., amine equivalent), excess di-n-butylamine wasadded to form a urea by reaction with the isocyanate groups. Thequantity of excess amine was determined by titration with a standardsolution of hydrochloric acid. The NCO or amine equivalent can bedefined as the weight of sample that reacts with one equivalent ofdibutylamine. The oligomer equivalent weight was determined by dividing100×equivalent weight NCO by the percent NCO.

For the above sample, the percent NCO as a portion of solids was 5.09%.Estimating the percent NCO using the quantities of material added andassume complete reaction yields 5.16%. The percent NCO as a portion ofsolution was 3.41%. The oligomer of the sample had an equivalent weightof (42.02×100)/3.41=1232 g/eq.

The representative procedure of Example 1 was repeated for the formationof additional urethane oligomers. The reactants and characteristics ofthese other urethane oligomers are tabulated in Table 1.

TABLE 1 Urethane Oligomers UO ID TDI/TMP/DIOL NCO-EW NCO-EW No. (byequivalence) NCO/OH DIOL (Solu.) (Solids) 1 2.0/0.0/1.0 2.00 PM-650895.9 610 2 2.0/0.0/1.0 2.00 KF-320 630 323 3 3.0/0.0/1.0 3.00 PM-650424 252 4 2.2S/0.0/1.0 2.25 PG-S5 643 369 5 2.5/0.0/1.0 2.50 PG-SS 609310 6 2.8/0.3/1.0 2.15 PM-650 652 371 7 2.55/0.3/1.0 1.96 PM-650 703 4518 2.3/0.3/1.0 1.77 PM-650 834 557 9 2.55/0.6/.7 1.96 PG-55 576 366 102.3/0.3/1.0 1.77 PG-55 788 523 11 2.55/0.5/.8 1.96 PM-650 634 405 122.55/0.3/1.0 1.96 PG-55 632 416 13 2.55/0.4/1.1 1.70 PM-650 649 56S 142.25*/0.25/1.0 1.8 PM-650 886 592 15 2.25*/0.14/1.0 1.97 PM-650 791 52316 2.25**/0/1.0 2.25 PM-650 834 528 UO ID N0. = isocyanate terminatedurethane oligomer identification number. TDI = toluene diisocyanate(Rhone-Poulenc, Shelton, CT) except as specifically indicated. TMP =2-ethyl-2-(hydroxymethyl)-1,3-propenediol (Perstorp, Toledo, OH). PM-650= polytetramethylene glycol (EW = 324, Great Lakes Chemical, Lafayette,IN). KF-320 = K-flex UD320, urethane diol (EW = 160, King Industries,Norwalk, CT). PG-55 = Poly G55-1731 ethylene oxide terminatedpolypropylene glycol (EW = 324, Olin Corp., Stamford, CT). NCO/OH =ratio of NCO equivalents to OH equivalents. NCO-EW (Solu.) = equivalentweight of urethane oligomer in solution based on NCO functionality priorto reaction with ketimine. NCO-EW (Solids) = equivalent weight ofurethane oligomer with solvent removed, based on NCO functionality priorto reaction with ketimine. *Isophorone Diisocyanate (Vestanate IPD ™,Creanova Corp., Somerset, NJ) substituted for TDI. **Methylenediisocyanate (Isonate 143L ™, Dow Chemical, Midland, Mi) substituted forTDI.

Example 2

Preparation of Ketimine

A ketimine was formed to later react with the isocyanate functionalizedurethane oligomer. To form the ketimine, 92.81 g of aminoethylpiperazine (AEP) and 207.19 g of MEK were added to a flask and left toreact for a couple of hours.

AEP has one functional primary amine for an equivalent weight of 129.Similarly, MEK has one equivalent per molecular for an equivalent weightof 72. It follows that a significant excess of MEK was added to reducethe amount of unreacted AEP. In particular, a three fold excess byequivalence of MEK was added. The product was analyzed by gaschromatography. From GC analysis, the ratios of equivalents of ketimineto AEP (unreacted) was 95/5.

If all of the AEP reacted to form ketimine, 417 g of the composition(including solvent) would correspond to 1 equivalent, and the equivalentweight would be 417 g. Any unreacted AEP, however, has two equivalentsper molecule since it can react with an isocyanate at both the primaryamine and the secondary amine. Assuming that 95 percent of the AEP hasformed ketimine, 5 percent remains as unreacted AEP. Similarly, with 417g corresponding to about 1.05 equivalents, the equivalent weight wasabout 399.

Example 3

Formation of Ketimine Terminated Urethane Oligomer

The prepolymer was separated into two equal parts. One part (485 g) ofthe urethane oligomer was added to a glass addition funnel. A 147.63 gquantity of ketimine/AEP product was placed into a 2000 ml reactionflask and gently stirred. After a couple of minutes of stirring, theurethane prepolymer was added to the reaction flask in a steady streamwhile stirring was continued. The exothermic nature of the reactionresulted in heating of the reaction flask to a temperature between 130°F. and 140° F. during the addition of the urethane oligomer. As theviscosity of the composition in the reaction flask increased duringaddition of the urethane oligomer, the mixing rate was increased tomaintain a satisfactory mix rate. The addition of urethane oligomer wascompleted after about 5-10 minutes. The addition funnel was then rinsedwith about 25 ml of MEK, which was subsequently added to the reactionflask. The reaction was terminated following addition of the rinsesolution.

The percent non-volatiles was determined by heating a sample or thereaction product in a dish at 220° F. for one hour. Again using theprocedure of ASTM D 2369-90, from a 0.6965 g portion, 56.86% of thesample remained after heating and from a 0.6552 g sample 56.67%remained. Estimating the percent nonvolatilves based on the quantitiesof reactants, assuming complete reaction, yields 56.77%.

Example 4

Formation of Amine-Terminated Urethane Oligomer

A 655.7 g quantity of the ketimine functionalized urethane oligomercomposition was placed in a flask. Based on the average non-volatilecontent, 372.24 g of material in the flask was non-volatile. A 33.50 gquantity of water and 178.68 g quantity of iso-propyl alcohol were addedto the flask. The mixture was stirred for about 15 minutes to ensurecomplete mixing. The water hydrolyzed the ketimine to remove the ketoneprotecting group, thereby converting the ketimine to an unprotectedprimary amine.

The mixture then was placed a rotary evaporation flask for removal ofreleased MEK by rotary evaporation. The flask was heated to atemperature from about 50° C. to about 55° C. under vacuum for about ahalf hour. A total of 337.85 g of solvent was removed. It is assumedthat essentially all of the methyl ethyl ketone was removed. The initialsolvent removed was 70/30 mixture of MEK/IPA corresponding to theazeotrope.

The percent non-volatiles (ASTM D 2369-90) in the final amine-terminatedurethane oligomer was determined by placing a two small samples (0.8115g and 0.7165 g) in a dish and heating to about 220° F. for about 2hours. The average of the two measurements (72.48% and 72.64%) yielded72.56% non-volatiles.

The above representative procedure described in Examples 3-4 wasrepeated approximately for the production of other amine-terminatedurethane oligomers. The reactants and characteristics of the resultingoligomers are summarized in Table 2.

TABLE 2 Amine-Terminated Urethane Oligomers ATUO UO ID No. ID No.Alcohol/Water Viscosity % Solids 1 1 50-55% BzOH 59.47 2 2 57% BzOH68.50 3 3 50% BzOH 60.40 4 4 4S% BzOH 63.30 5 5 40% BzOH 66.75 6 6 40%BzOH 65.96 7 7 40% BzOH 68.22 8 8 40% BzOH 63.97 9 9 40% BzOH 68.97 1010 40% BzOH 67.20 11 11 40% BzOH 66.34 12 7 20% BzOH + 20% IPA 66.16 137 30% BzOH + 10% IPA 77.47 14 7 36% BzOH + 4% IPA 74.49 15 7 40% IPA69.83 16 7 60% IPA 63.48 post add 5% AEP + 10% BzOH 17 7 20% BzOH + 20%n-butanol 69.17 post add 5% AEP 18 7 30% BzOH + 10% n-butanol 67.38 postadd 5% AEP 19 1 40% BzOH 67.27 20 7 45% IPA + 12% water 67.00 21 7 45%IPA + 12% water 66.28 post add 3% IPA + 10% BzOH 22 7 45% IPA + 17%water 72.37 23 7 45% IPA + 13% water 24 1 45% IPA + 13% water 68.88 2512 45% IPA + 13% water 72.91 26 13 47% IPA + 12% water 76.63 27 14 48%IPA + 9% water 16900 77.67 28 15 48% IPA + 9% water 12400 75.86 29 1660% IPA + 9% water 68.36 ATUO ID No. = Identification Number for theAmine-Terminated Urethane Oligomer. UO ID No. = Isocyanate terminatedurethane oligomer identification number corresponding to numbers inTable 1. Alcohol/Water = Weight percents added alcohol and/or wateradded to the ketimine terminated urethane oligomers based on weight ofoligomer solids. Viscosity = Brookfield Viscosity of amine-terminatedurethane oligomers following removal of MEK as measured by ASTMD2196-86(1991). % Solid = percent by weight of the non-volatilecomponent of the amine-terminated urethane oligomer as determinedfollowing ASTM D2369-90.

Example 5

Copolymer

The amine-terminated urethane oligomers were ready for mixing with aepoxy resin, crosslinking agent. The two solutions were poured togetherand blended with a spatula or the like. The blend was then be applied asa three mil (wet) film to a glass substrate to determine the basicproperties of the coating. Various blends that were prepared and theirproperties are summarized in Tables 3 and 4.

TABLE 3 Urethane/Epoxy Copolymers-König Hardness Cop ATUO König HardnessID No. ID No. BPAGE/Mono Day 1 Day 2 Day 3 Week 2 1 1 85/15 11 24 45  672 2 85/15 9 21 43  58 3 3 85/15 21 56 69  97 4 4 85/15 12 17 26  46* 5 585/15 16 21 —  74* 6 6 92/8 20 51 74 162 7 7 85/15 22 42 71 140 8 7 92/820 44 71 153 9 8 85/15 19 36 53 123 10 8 92/8 12 32 48 140 11 9 92/8 1428 45 123 12 10 92/8 11 12 16  65 13 7 85/15 14 28 49 137 14 7 8S/15 1330 57 135 15 7 92/8 13 23 41 137 16 7 92/8 13 23 41 126 17 11 85/15 1428 47 138 18 11 92/8 15 29 45 134 19 7 85/15 23 48 77 147 20 7 92/8 2646 78 155 21 13 85/15 38 63 84 144 22 13 92/8 39 71 86 148 23 14 85/1548 77 91 142 24 14 92/8 47 78 92 150 25 15 85/15 62 82 95 142 26 15 92/859 88 104 152 27 19 92/8 13 24 39 125 28 20 92/8 19 30 48 147 29 21 92/814 20 35 143 30 22 92/8 73 100 106 154 31 24 92/8 60 70 77 139 32 2S92/8 41 51 57 140 33 26 92/8 59 83 98 146 34 26 85/15 + 1.7% 55 77 90136 BZOH 35 27 92/8 40 76 99 134 36 28 92/8 41 75 100 137 37 29 92/8 6789 112 155 Cop ID N0. = Copolymer identification number. ATUO ID N0. =Amine-terminated urethane oligomer identification number correspondingto values in Table 2. BPAGE/Mono = Relative proportions by weight ofdiglycidyl ether of bisphenyl A (BPADGE, EW 185-192, EPON 828 ™, ShellChemical, Houston, TX) and monofunctional Epoxide 8 (C12-C14monoglycidal ether of C12-C14 alcohol, EPOTUF 37-058, Reichold Chemical,Research Triangle Park, NC) to produce a 1:1 equivalence ratio with theamine-terminated urethane oligomer. The final copolymer included 1.7percent by weight benzyl alcohol. König Hardness: as measured 1 day, 2days, 3 days or two weeks following application of the coating.

TABLE 4 Urethane/Epoxy Copolymers-Additional Properties Cop ID No. 2 WkTaber Tensile Strength % Elong. Range 1 12 3800 5600 2 64 3000 6300 3 332600 4900 10-40 7 49 8 31 9 33 10 28 11 57 12 26 21 29 22 26 23 27 24 2725 31 26 33 30 32 4600 6700 10 31 22 2300 3400  5-10 32 33 2200 4800 5-10 33 34 3700 5800  5-10 34 24 3100 5200 10-20 35 44 36 39 37 29 CopID No. = Copolymer identification number. 2 Wk Taber = Abrasionresistance measured using a Taber Abrasor, 2 weeks after application ofthe coating. Tensile Strength = Average tensile strength measuredfollowing ASTM D 2370-92 in pounds per square inch generally based on atleast six independent measurements. % Elong. = Percent elongationmeasured following ASTM D 2370-92.

Example 6

Systematic Study of Urethane-Epoxy Coating Properties

In this example, the properties of urethane-epoxy coatings similar tothose described above are systematically studied. In particular, theurethane oligomers are varied along with the relative amounts.ofketimine and epoxy resin.

The procedures followed to produce these coatings were comparable tothose described in the preceding examples. All of the urethane oligomerswere produced using a ratio of 2.25 TDI/1.0 PM-650 by equivalence. Theamounts of triol TMP was varied as indicated. Ketimine was prepared asdescribed in Example 2. The amine terminated urethane oligomers producedare summarized in Table 5.

TABLE 5 ATUO ID No. TMP (eq) NCO/Ket % NV cps aew (sol'n) 6-1 0.00 0.87778.44 141,000  442 6-2 0.00 0.940 73.18 22,700 448 6-3 0.00 1.000 77.84N/A 376 6-4 0.00 1.065 75.11 22,900 370 6-5 0.14 0.877 75.3 75,500 5166-6 0.14 0.940 72.76 50,300 507 6-7 0.14 1.000 72.28 12,700 437 6-8 0.141.065 71.24 12,400 419 6-9 0.25 0.877 75.73 70,000 506 6-1O 0.25 0.94078.57 103,000 466 6-11 0.25 1.000 71.22 25,700 468 6-12 0.25 1.065 73.6425,200 432 6-13 0.40 0.877 74.84 107,000 611 6-14 0.40 0.940 72.9347,400 588 6-15 0.40 1.000 76.53 58,100 499 6-16 0.40 1.065 70.27 36,600506 6-17 0.60 0.877 74.72 >100,000*  759 6-18 0.60 0.940 72.56 118,000 727 6-19 0.60 1.000 71.07 65,800 657 6-20 0.60 1.065 69.44 39,100 630*Apparatus did not yield accurate result. ATUO ID-No. = Amine-terminatedurethane oligomer identification number. TMP(eq) = Equivalents of TMPadded to form the urethane oligomer. NCO/Ket = Theoretical ratio ofequivalents of NCO and ketimine functionalities. % NV = Theoreticalestimates of percent nonvolatiles. cps = Brookfield Viscosity incentipoise (ASTM D 2196-86 (1991). aew (sol'n) = Amine equivalent weightin solution.

The amine terminated urethane oligomers were used to produceurethane-epoxy coatings, as described in Example 5. The epoxy resin usedto produce the coating was 95% BPADGE and 5% Epoxide 8 by weight. Theproperties of the resulting coatings are summarized in Table 6.

TABLE 6 eq NH/ ATUO eq 1 day 2 day 3 day 1 wk 2 wk 1 wk ID-No. epoxyKönig König König König König Taber 6-1 0.8 31 43 55 92 125 21 1 51 6982 116 141 12 1.2 69 92 106 136 155 14 6-2 0.8 41 56 71 109 139 33 1 6285 102 137 155 12 1.2 81 109 125 156 168 17 6-3 0.8 32 46 92 140 157 271 48 76 123 155 165 19 1.2 60 92 141 161 168 16 6-4 0.8 40 60 108 147166 40 1 60 87 136 158 171 23 1.2 63 96 146 165 168 15 6-5 0.8 30 46 6497 125 21 1 22 42 75 108 132 22 1.2 57 88 111 139 155 19 6-6 0.8 29 5072 109 135 29 1 48 79 102 135 155 19 1.2 61 96 122 148 165 18 6-7 0.8 4364 83 126 152 32 1 58 87 107 146 161 26 1.2 78 108 128 160 175 19 6-80.8 42 73 89 134 159 44 1 65 100 118 153 168 27 1.2 81 119 134 163 17421 6-9 0.8 24 38 48 81 102 21 1 32 53 67 98 111 12 1.2 48 76 92 120 13014 6-10 0.8 31 48 60 91 115 33 1 29 50 65 106 124 12 1.2 54 90 107 136145 17 6-11 0.8 46 67 85 126 146 30 1 67 95 113 146 158 21 1.2 76 106123 156 164 18 6-12 0.8 43 65 87 126 147 41 1 61 90 109 144 158 26 1.272 106 125 151 164 20 6-13 0.8 18 21 29 44 71 21 1 29 38 51 62 87 22 1.235 49 66 76 95 19 6-14 0.8 22 30 42 58 86 29 1 36 50 68 87 103 19 1.2 3860 81 96 114 18 6-15 0.8 34 60 69 105 129 15 1 44 83 92 125 137 17 1.247 90 103 132 143 12 6-16 0.8 38 64 74 111 136 41 1 58 94 104 132 146 231.2 69 109 119 146 153 16 6-17 0.8 26 33 40 52 73 15 1 32 46 55 61 84 131.2 39 54 64 78 94 14 6-18 0.8 29 40 48 63 87 28 1 36 54 65 81 99 17 1.248 67 80 94 113 1 6-19 0.8 39 53 67 92 115 23 1 53 73 87 108 122 19 1.258 82 98 120 130 15 6-20 0.8 39 51 68 93 114 35 1 54 69 89 112 127 151.2 60 85 100 123 132 19 ATUO ID-No = Amine terminated urethane oligomeridentification number. eq NH/eq epoxy = Theroetical ratio of NHfunctional groups and epoxy functional groups. König = König Hardness asmeasured 1 day, 2 days, 3 days, 1 week or two weeks followingapplication of the coating. 1 wk Taber = Abrasion resistance measuredusing a Taber Abrasor, 1 week after application of the coating.

The embodiments described above are intended to be representative andnot limiting. Additional embodiments of the invention are within theclaims.

What is claimed is:
 1. A kit comprising: a) a composition comprisinggreater than about 55 percent by weight amine-terminated urethaneoligomers free of crosslinking between a terminal amine and anisocyanate linkage, and the composition being substantially free ofketones and aldehydes; and b) A polyepoxide compound in a containerseparate from said composition comprising amine-terminated urethaneoligomers.
 2. The kit of claim 1 wherein said polyepoxide is apolyglycidyl ether of a polyphenol, a polyglycidyl ether of aliphaticpolyol with 2 to 4 hydroxyl groups, or mixtures thereof.
 3. The kit ofclaim 1 wherein the ratio of active hydrogens in amine functional groupsto epoxide groups ranges from about 1:1 to about 1.75:1.
 4. A polymercoating comprising an epoxy crosslinked amine-terminated urethanepolymer, said coating formed by curing a mixture of polyepoxides and acomposition comprising greater than about 55 percent by weightamine-terminated urethane oligomers free of crosslinking between aterminal amine and an isocyanate linkage, wherein said mixture has ratioof active hydrogens to epoxide groups that ranges from 1.25:1 to about2:1.
 5. A method of forming a coating comprising the steps of spreadinga mixture on a surface such that it can cure, the mixture being obtainedby mixing polyepoxides with a composition comprising greater than about55 percent by weight amine-terminated urethane oligomers free ofcrosslinking between a terminal amine and an isocyanate linkage, and thecomposition being substantially free of ketones and aldehydes.
 6. Themethod of claim 5 wherein said surface comprises concrete.
 7. The methodof claim 5 wherein said surface is a floor or a wall.
 8. The kit ofclaim 1 wherein the composition comprises from about 60 percent to 90percent by weight amine-terminated urethane oligomers.
 9. The kit ofclaim 1 wherein the composition comprises from about 65 percent to 80percent by weight amine-terminated urethane oligomers.
 10. The kit ofclaim 1 further comprising an aqueous viscosity modifying agent.
 11. Thekit of claim 10 wherein said aqueous viscosity modifying agent comprisesgreater than about 30 percent by weight volatile alcohol.
 12. The kit ofclaim 1 further comprising volatile organic acids, said compositioncomprising less than about 1 percent by mole equivalent of carboxylategroups of said volatile organic acids relative to amine groups of saidamine-terminated urethane oligomers.
 13. The kit of claim 1 wherein saidamine-terminated urethane oligomers comprise multifunctional aminemoieties bonded at secondary amine sites to isocyante functional groupsof a urethane oligomer to form urea linkages.
 14. The kit of claim 13wherein said multifunctional amine moieties compriseN-(aminoethly)piperazine moieties.
 15. The kit of claim 1 wherein saidamine-terminated urethane oligomers comprise amine moieties bonded at anoxygen atom to isocyanate functional groups of a urethane oligomer toform carbamate linkages.
 16. The kit of claim 1 wherein saidamine-terminated urethane oligomers are free of —NCON—R₁—NOCN— linkagesbetween isocyanate groups, where R₁ is a hydrocarbon moiety.
 17. Themethod of claim 5 wherein the composition comprises from about 65percent to 80 percent by weight amine-terminated urethane oligomers. 18.The method in claim 5 further comprising an aqueous viscosity modifyingagent.
 19. The method of claim 18 wherein said aqueous viscositymodifying agent comprises greater then about 30 percent by weightvolatile alcohol.
 20. The method of claim 5 wherein saidamine-terminated urethane oligomers comprise multifunctional aminemoieties bonded at secondary amine sites to isocyanate functional groupsof a urethane oligomer to form urea linkages.